Engine removal

usermjg · Jan 2, 2009

Hi

I have a 1977, 2.7 911 which really need some TLC. I thought the best thing to do would be remove the engine and gearbox from the car and then work on these at my leasure, well the engine anyway. Im pritty ok with a spanner, so not to worried about the job itself, however are there any tips or tools i might need before i go ahead? I have on order a big trolley jack, with a 825 mm lift height and two massive axle stands. My plan is to jack the front up alittle and then the back, after removing the rear bumber. Putting the axles stands under the torson bars, and lowering the engine/gearbox from there. Obviously I'm abit of a whimp as to the weather and will not be starting until it gets abit warmer.

bones · Jan 2, 2009

Marc although removing a 911 engine can be done by one person according to the factory manual, these are Uber Mechanics trained in Stuttgart's secret Uber School. Find two mates to help, the engine is too precious to drop. Post here to see if you can find some peole in your area or if you have no luck, try impactbumpers.co.uk or DDK. You don't need to remove the rear bumper or jack up the front of the car, put chocks under the front wheels and jack the rear up high enough to clear the engine, then lower onto the rear axle stands. You can choose to split the engine or not before removal. If you can find an experienced engine remover, so much the better, you might be able to persuade a Porsche Independent mechanic to come and help for a fee. Good luck.

idc1873 · Jan 3, 2009

ORIGINAL: usermjg

Did mine on my own, pretty straight forward.

As bones says, http://www.impactbumpers.com/forum/index.php?showtopic=7870

usermjg · Jan 3, 2009

ORIGINAL: idc1873

ORIGINAL: usermjg

Did mine on my own, pretty straight forward.

As bones says, http://www.impactbumpers.com/forum/index.php?showtopic=7870

Click to expand...

Really, good to hear from some one who has tackled the job, started to wonder weather i was barking mad to even attempt it.[8D]

911hillclimber · Jan 3, 2009

I've removed my 3.2 about 15 times in my 20 years 'life' with my car.( I hill climb my 911 so every year it get's a doing-over)
It is a one-man job, but the engine/box are very large and very heavy when 'free'. Balancing them on a big (or very big) trolley jack is asking for trouble IMHO.

My method is:

Get a good engine hoist (you can hire them)
Jack the rear end up about 28'' (I think) from floor to the rear bumper lower lip, so the engine can be dragged from under the car when out and down. No need to remove the rear bumper set.
I find a plank of 6 x 2 wood running across the full width of the rear floor pan just where the gear shift rod comes out and normal Halfords axle stands under the plank will get the rear at the right height. Beware that this is the very balance point of the car so keep the weight in the front, ie leave the battery in there, spare wheel etc to keep the nose down! One early removal adventure I found I had the entire car sitting on the jack balanced at that very point....[&:]
Drain the oil: there is about 12 litres of the black fast flowing quick spreading stuff so BE READY FOR IT! A large Halfords drain tray (big black round one) is NOT capacious enough!

As they say:

You have never known excitment until you drain the oil out of a hot 911[>:]

Disconnect everything, battery feed/ drive shafts/electrics/fuel/ gearbox linkage/throttle linkage/ heater ducting/ speedo cable/ rear anti roll bar/ oil lines to dry sump tank/ starter motor leads/ clutch cable.
(I think that's everything)
Lash the engine to the hoist with the boom poking inside the engine bay. With the weight on the rope/chain the boom must be just touching the engine lid underside. Why? because the boom needs to drop the engine/box right down to the floor, at least 28'' remember.
With the engine tight on the boom, place the jack under the engine about where the oil drain plug is ish. Take the weight on the jack.
Undo the 4 big bolts, 2 x gearbox cross member and 2 x engine cross beam. The engine / box weight can be gently eased onto the hoist.

It is here the brave single handed mechanic will be cool because the hoist is taking the strain, or very bothered because the whole lot is balanced on a silly jack. Your choice, it only weighs about 5 x your weight....
If sticking with the jack find two mates who are strong and obedient, and will do as you ask.

Lower the whole lot slowly to the ground. It is here that a shallow trolly about 2 to 3'' high is a god send (I made one in the end) as you can drop it on top of the trolly and pull the lot smoothly away from under the car. A Draper transmission jack is a good substitute but expensive.

It is harder to put it back in.[

]

Hope that helps. The 3.2 is much the same as the SC and is the same as a 2.4.

Have fun when the weather is better.[

]

l2015 · Jan 3, 2009

excellent post ,good one for reference

usermjg · Jan 4, 2009

thank you for your reply, it really helps alot. Not to sure why i didnt think of the engine hoist before, you make a very good point, and using one is in my mind the only way forward now that you metion it. Thank you again.

911hillclimber · Jan 4, 2009

Best be safe than sorry, and keep all your fingers...and other bits in-tact [

]

A good tow rope is a good sling for the engine.

sailor · Jan 5, 2009

Flipping heroes, all of you. Makes me break out in a cold sweat just thinking about it.

JohnC
993turbo

911hillclimber · Jan 5, 2009

It is a snip of a job compared to reoving an Impreza box, let alone the engine as well.
I've done that a few times too on my (now sold) hillclimber.

The killer is getting the lot back in as gravity sure tries to get in the way. [

]

Cars are a Bad Hobby to follow[&:]

usermjg · Jan 5, 2009

Upon reflection I might get someone else to whip the engine gearbox out, im not a wimp [

] but the thought of dropping it either on getting it out or back in worries me. In fact the getting out i think will be quite straight forward, i think the trick is getting it back in. Well im in no rush, i need to read some more and think, however im very greatful to all who have given me very valued advise.

bones · Jan 5, 2009

It's my fault isn't it? I put that element of doubt in your mind! [

] it's probably quite easy once you've done it, like the experienced engine pullers say here but also you'd never forgive yourself if you damaged it. If you can't get anyone to help, then do what I did, get an Independent to take the engine and box out and take it back to your place to work on. They fit in an Estate - just [

] Good luck.

911hillclimber · Jan 6, 2009

Bones is dead right. The engine/box is huge when loose of the car shell, but if you split it after it is out then 2 good guys can lift each lump and place in a good boot. (BMW 3 series is fine)

Buy a cheap Clark engine stand from Machine Mart and life will be so much sweeter. It is the only way to deal with the engine from setting the valve tappets to a crankshaft-up rebuild.

Getting the exhaust manifolds off is the most fun you can ever have on a 911.....[8|]

bones · Jan 6, 2009

Don't forget the engine stand will have to be able to accomodate one of these.

http://www.paragon-products.com/product_p/p201.htm

You can get them a lot cheaper, just search google.

911hillclimber · Jan 6, 2009

That is luxury! Used to see them at the Autojumble at Husband Crawley.[

]

Gary71 · Jan 7, 2009

Take it out yourself, you know you want too

It's really not that bad. I made a trolley with 4 big castors, some 2"x4" and a sheet of 15mm MDF on top. After jacking the car like mentioned above I then placed the trolley under the engine with the trolley jack under the trolley (where else

) Undo everything and gently lower it down, you don't even need to take the rear bumper off if you are careful. The only fiddly bit is getting the gearshift rod out of the tunnel (and hence back in again) whilst the assembly is pearched on the jack. Then the whole lump is on a nice trolley you can wheel around the garage at your leisure.

I did it in just over an hour the first time.

Now I can do it in my sleep (although not as deep a sleep as 911 hillclimber!!!)
Gary

usermjg · Jan 7, 2009

Still in two minds, plus i have been given a really good qoute for the car to be picked up, and dropped back off again. [

]

chris.hevey · Jan 7, 2009

ORIGINAL: usermjg

Still in two minds, plus i have been given a really good qoute for the car to be picked up, and dropped back off again. []

I was thinking that. Just put a stand under the engine and pick the whole car up. Brilliant plan!

usermjg · Jan 7, 2009

ORIGINAL: chris.hevey

ORIGINAL: usermjg

Still in two minds, plus i have been given a really good qoute for the car to be picked up, and dropped back off again. []

Click to expand...

I was thinking that. Just put a stand under the engine and pick the whole car up. Brilliant plan!

Sorry i meant, a good quote for the car to be picked up from where i live, work to be carried out and guarented and then dropped back off to my doorstep.